Safety system and method for detecting structural damage in electrolysis stacks

Abstract

The invention relates to a safety system (1) comprising a detector (2) for detecting structural damage in an electrolysis stack (3) having a plurality of electrolysis cells (4), wherein the detector (2) may be in the form of an optical sensor, an ultrasonic sensor, a contact strip for mechanical detection, a spatial acoustic monitoring system, a structure-borne sound monitoring system at end plates of the electrolysis stack, or a sensor system in blind flanges, gas distributors, or gas collectors. The invention also relates to an electrolysis plant comprising such a safety system (1) and to a method for detecting structural damage in an electrolysis stack (3).

Description

2024PF00123 1 Description TITLE Safety system and method for detecting structural damage in electrolysis stacks TECHNICAL GEF-MFI

[0001] The present invention relates to a safety system with a detector for structural damage in electrolysis stacks and to an electrolysis plant with such a safety system. The present invention further relates to a method for detecting structural damage in an electrolysis stack. BACKGROUND

[0002] Electrolysis stacks are used in various industrial applications, particularly in hydrogen production via electrolysis. Electrolysis stacks consist of numerous electrolysis cells, typically arranged in series of approximately 20 to 300 cells, with 50 to 200 cells being the most common configuration. The structural integrity of these electrolysis stacks is crucial for their safe and efficient operation.

[0003] Various failure scenarios, such as fire or pressure surges, can lead to the partial destruction of one or more electrolysis cells. This, in turn, can result in the release of media such as hydrogen (H2), oxygen (O2), and water, posing significant safety risks, including the danger of fires, explosions, and high-energy hot water leaks. Therefore, there is a need for reliable systems and procedures for the early detection of such damage. SUMMARY OF THE INVENTION

[0004] The object of the invention is to provide a safety system in electrolysis stacks and an electrolysis plant with such a safety system. 2024PF00123 2 further states that the object of the invention is to provide a method for detecting structural damage in an electrolysis stack.

[0095] The task directed towards a safety system is solved by a safety system with a detector for structural damage in an electrolysis stack with a multitude of electrolysis cells, wherein the detector can be designed as an optical sensor, ultrasonic sensor (H2 changes the speed of sound), contact strip for mechanical detection, room acoustic monitoring, structure-borne sound monitoring on end plates of the electrolysis stack or as sensors in blind flanges, gas distributors or gas collectors.

[0006] Depending on the method, various advantages and limitations arise. Gas leakage monitoring using optical sensors, for example, requires a clear line of sight. They enable the detection of gas leaks via infrared radiation. Contact strips, similar to those used in shop window break-in detection, can detect mechanical changes or breaks. Acoustic monitoring uses acoustic sensors to capture noises that indicate a frame break or leak. Structure-borne sound sensors on the end plates of electrolysis stacks can detect vibrations and sound waves caused by cracks or leaks. Appropriate sensors in blind flanges and gas distribution or collection lines can also be used to monitor pressure, differential pressure, and structure-borne sound to detect leaks and frame breaks.These various detection methods enable comprehensive monitoring of the structural integrity of the electrolysis stack. It is advantageous if the safety system according to the invention is designed to detect specific structural damage such as frame fractures of electrolysis cells, leaks, or heat sources. This damage can significantly impair the functionality and safety of the electrolysis stack, which is why its early detection is of great importance. 2024PF00123 3 In an advantageous embodiment of the invention, the security system comprises a control unit, wherein the detector is connected to the control unit.

[0009] Advantageously, the detector is configured to generate an alarm signal based on a measured value and transmit this alarm signal to the control unit. This alarm signal enables immediate countermeasures to minimize potential hazards and ensure safe operation.

[0010] Alternatively, if the detector is configured to transmit a measurement value to the control unit, and the control unit is configured to issue an alarm based on the measurement value received from the detector, it may also be useful.

[0011] It is particularly advantageous if the control unit is configured to use an AI-based evaluation algorithm that takes into account media requirements, gas production volumes, power supply, or mass balances. AI algorithms can be employed that evaluate a multitude of operating parameters and their development / change over time, and detect deviations from the initial state. For example, the differential pressure between the oxygen and hydrogen sides, as well as the water consumption per unit of gas produced, can be used for evaluation. Sudden changes during operation can be an indicator of structural damage. Fundamentally, the strength and scope of artificial intelligence are characterized by its ability to operate even in completely unstructured environments.It is sufficient to specify only global requirements in order to detect changes in patterns and react accordingly with alarm messages or shutdowns.

[0012] Advantageously, an electrolysis system with an electrolysis stack includes a safety system according to the invention. This ensures that the electrolysis system is continuously monitored for structural damage and that immediate action can be taken if necessary. 2024PF00123 4

[0013] The problem addressed by this method is solved by a method for detecting structural damage in an electrolysis stack with a plurality of electrolysis cells. This method involves detecting the level of infrared radiation in the electrolysis stack using an infrared detector, detecting gas leaks at the electrolysis stack via a contact strip, acquiring room acoustic data, detecting structure-borne sound at the end plates of the electrolysis stack, or acquiring data from sensors in blind flanges, gas distributors, or gas collectors. This method enables comprehensive and reliable monitoring of the structural integrity of the electrolysis stack.

[0014] It is advisable to issue an alarm signal if a limit value of the recorded data is exceeded.

[0015] Furthermore, it can also be advantageous if the electrolysis stack is switched off when the alarm signal is issued.

[0016] The present invention offers an improved safety solution, for example, in the event of a cell frame failure in an electrolysis plant. Implementing this solution effectively prevents the escape of significant quantities of gas and process water from the gas separators, as well as from the upstream manifolds and electrolysis stacks. This is crucial because an uncontrolled release of these substances could have serious safety consequences. Particularly in large electrolysis plants comprising numerous electrolysis stacks and extensive process components, the invention ensures safer operation and minimizes the risk of safety-related incidents. SHORT DESCRIPTION OF THE DRAWINGS FIG 1 shows an electrolysis plant according to the invention. 2024PF00123 5 DESCRIPTION OF THE EXECUTION FORMS

[0018] FIG. 1 illustrates by way of example an electrolysis system 6 according to the invention, comprising four electrolysis stacks 3, each electrolysis stack 3 comprising several electrolysis cells 4. The electrolysis system 6 is equipped with a safety system 1 according to the invention, comprising detectors 2 assigned to the individual electrolysis stacks 3, and a control unit 5. The detectors 2 are intended to detect structural damage such as frame fractures of electrolysis cells 4 or leaks and are connected to the control unit 5.

[0019] A detector 2 can be configured to generate an alarm signal based on a measured value and transmit this alarm signal to the control unit 5. Alternatively, a detector 2 can be configured to transmit a measured value to the control unit 5, which is then configured to issue an alarm based on the measured value received from detector 2 if limit values ​​are exceeded.

[0020] The invention is not limited to the number of electrolysis stacks 3 shown in the embodiment of FIG. 1, nor to the number of detectors 2 shown. In principle, the number of detectors 2 for one electrolysis stack 3 can also differ from the number of detectors 2 for another electrolysis stack 3. The detectors 2 can also differ in their type; for example, they may be configured as infrared sensors, contact strips for mechanical detection, room acoustic monitoring, structure-borne sound monitoring at end plates of the electrolysis stack, or as sensors in blind flanges, gas distributors, or gas collectors.

[0021] The Kl 7 in control unit 5 enables the electrolysis plant to recognize patterns and relationships in data in order to make predictions or solve problems. For this purpose, the Kl technology uses various external signals such as differential pressure, mass flow rates, and other relevant measured variables to acquire and process real-time data. This allows it 2024PF00123 6 of the class, to identify complex patterns and trends in the data and to take appropriate actions. REFERENCE MARK LIST 1 Security system 2 Detector 3 Electrolysis stacks 4 Electrolysis cell 5 Control unit 6 Electrolysis plant

Claims

2024PF00123 7 Claims What is claimed:

1. Safety system (1) with a detector (2) for structural damage in an electrolysis stack (3) with a plurality of electrolysis cells (4), wherein the detector (2) can be designed as an optical sensor, ultrasonic sensor, contact strip for mechanical detection, room acoustic monitoring, structure-borne sound monitoring on end plates of the electrolysis stack or as sensor technology in blind flanges, gas distributors or gas collectors.

2. Safety system (1) according to claim 1, wherein structural damage includes frame fractures of electrolysis cells (4), leaks or heat sources.

3. Security system (1) according to one of claims 1 or 2, comprising a control unit (5), wherein the detector (2) is connected to the control unit (5).

4. Safety system (1) according to claim 3, wherein the detector (2) is configured to generate an alarm signal based on a measured value and to transmit this alarm signal to the control unit (5).

5. Security system (1) according to claim 3, wherein the detector (2) is configured to transmit a measured value to the control unit (5) and wherein the control unit (5) is configured to issue an alarm based on the measured value received from the detector (2).

6. Safety system (1) according to one of claims 3 to 5, wherein the control unit (5) is configured to use a computer-based evaluation algorithm and to take into account media requirements, gas production quantities, power supply or mass balances.

7. Electrolysis system (6) comprising an electrolysis stack (3) and a safety system (1) according to one of the preceding claims. 2024PF00123 8 8. Method for detecting structural damage in an electrolysis stack (3) with a plurality of electrolysis cells (4), wherein a level of infrared radiation in the electrolysis stack (3) is detected by means of an infrared detector, wherein gas leaks at the electrolysis stack (3) are detected via a contact strip, wherein room acoustic data are detected, wherein structure-borne sound at end plates of the electrolysis stack (3) is detected, or wherein data from sensors in blind flanges, gas distributors or gas collectors are detected.

9. The method of claim 8, wherein an alarm signal is issued if a limit value of the recorded data is exceeded.

10. The method of claim 9, wherein the electrolysis stack (3) is switched off when the alarm signal is issued.

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